Fire blocking method and apparatus

ABSTRACT

A pallet assembly includes at least one pallet member having external surfaces and a flame retardant material affixed to at least one pallet member so as to substantially cover all of the external surfaces of the pallet member. A pallet includes a container, tote bin, or any other suitable device used for the storage and transportation of items. In accordance with the invention, a method of fire blocking a pallet assembly includes the step of providing a pallet assembly that can include at least one pallet member having external surfaces. The method also can include affixing a flame retardant material to at least one pallet member so as to substantially cover all of the external surfaces of the pallet member.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] (Not Applicable)

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] (Not Applicable)

BACKGROUND OF INVENTION

[0003] 1. Technical Field

[0004] The present invention relates generally to fire blocking. Moreparticularly, the invention relates to the fire blocking of pallets.

[0005] 2. Description of the Related Art

[0006] Several approaches have been used to develop pallets withenhanced physical properties. Many of these approaches incorporate theuse of various mixtures of compositions to enhance the physicalproperties of pallets. Specifically, these compositions attempt toincrease flame resistance, durability, and strength of pallets. One typeof composition that has been utilized includes nanocomposite technology.Nanocomposites utilize many different materials that are intermingled ona nanometer scale. The use of nanocomposites to develop high temperaturecompositions with enhanced thermal stability and performancecharacteristics is disclosed in U.S. Pat. No. 6,057,035 to Singh. Theinvention in Singh provides high-use temperature, lightweightpolymer/inorganic nanocomposite materials utilizing techniques thatenhance the thermal stability of the nanocomposite systems from theircurrent limits of 100-150° C. to over 250° C. Additionally, muchresearch has been focused on the development of flame retardantmaterials in combination with fabrics to provide flame retardantqualities. Combining flame retardant materials with fabric is generallyknown. For instance, U.S. Pat. No. 4,950,533 to McCullough, Jr.discloses fabrics comprising a blend of substantially permanently orirreversibly heat set, non-flammable, carbonaceous fibers with polymericfibers. Considerable time and effort has been expended in commercialindustry to develop nonflammable and flame retardant fabrics. In thearea of pallet technology, the efforts have focused on increasing apallet's ability to retard fire by the usage of methods involving thecombinations of flame retardant materials in the composition of pallets,such as during the molding process. Additionally, the pallets in theprior art are monolithic in structure and incur difficulty whenattempting to meet fire performance standards. Flame retardancy in thepallet industry is preferably measured according to the Underwriters'Laboratory UL-2335 and/or FMRC fire performance protocol. Otherorganizations, such as the Grocery Manufacturing Association (GMA) andOSHA impose size and other restrictions on pallets depending on itsparticular purpose. These standards set minimum requirements that ensurefire safety and performance in the pallet industry.

[0007] Unfortunately, past efforts conducted to develop palletsexhibiting superior flame resistance have been problematic. Difficultyhas been encountered in attempting to qualify pallets under standardsafety guidelines, such as UL-2335. The problem to be solved is indeveloping a warehouse material handling pallet that meets theendurance, dimensional, load bearing, and weight parameters outlined bythe Grocery Manufacturers Association (GMA) and OSHA ergonomicrequirements while meeting the Factory Mutual Research Corporation andUnderwriters Laboratories, Inc. Standard UL 2335 fire performanceprotocols. Consequently, there is a need for a pallet structure thatmeets the standards under these regulatory test concerning flameretardancy, while remaining cost efficient and effective for itsparticular purpose.

SUMMARY OF INVENTION

[0008] The present invention relates to an apparatus and method of fireblocking a pallet assembly that enhances the physical attributes of thepallet assembly while providing flame retardancy.

[0009] A pallet assembly according to the invention comprises at leastone pallet member having external surfaces and a flame retardantmaterial affixed to at least one pallet member so as to substantiallycover all of the external surfaces of the pallet member. A pallet caninclude a container, tote bin, or any other suitable device used for thestorage and transportation of items.

[0010] In accordance with the invention, a method of fire blocking apallet assembly comprises the steps of providing a pallet assembly thatcan include at least one pallet member having external surfaces. Thenext step can include affixing a flame retardant material to at leastone pallet member so as to substantially cover all of the externalsurfaces of the pallet member.

[0011] In this invention, a flame retardant material provides a coveringto the pallet member and increases the fire performance of the palletassembly. The flame retardant material utilized can increase the overallsafety of the pallet assembly while providing enhanced physicaldurability. Flame retardant material suitable for use in this inventioncan include a flame retardant fabric. Affixing the flame retardantfabric to the pallet assembly provides resiliency to open flames. Openflames and other heat sources are common causes of pallet meltdown, thuscreating dangerous fire hazards during storage and transportation.Affixing the flame retardant fabric to a pallet protects and preventsdamage resulting from fire related occurrences and normal wear and tear.A blend of polymeric fibers can be included in the flame retardantfabric. The flame retardant fabric can be adapted to the dimensions ofthe pallet member. Adapting the flame retardant material to thedimensions of the particular pallet member can permit individualcomponents of the pallet member to be fabricated. The flame retardantmaterial also can include a flame retardant liquid. The flame retardantliquid can comprise an intumescent material. The intumescent materialcan be applied to a pallet member using a brush, roller or spray similarto application of ordinary paint. Required coating thickness depends onthe substrate, severity of the heat exposure, and level of protectiondesired. The flame retardant material utilized also can include a flameretardant polymer such as polyetaraflouraethylene. Flame retardantsynthetic fibers such as polyolefin fiber also can serve as the flameretardant material. Polyester and melamine fibers can also be utilizedas the flame retardant material on the particular pallet member.Additionally, the application of flame retardant materials can provideaesthetic value to a pallet along with providing pallet assemblyprotection and flame retardancy.

[0012] In an embodiment of the present invention the flame retardantmaterial can include a flame retardant metal. Stainless steel, copper,and aluminum are examples of metals that exhibit strong heat resistancewhile maintaining malleability which allow these metals to be integratedinto a pallet assembly. The flame retardant material also can utilizenanocomposite technology in covering a pallet assembly. Nancompositesutilize many different materials intermingled on a nanometer scale.Nanocomposites can be made from a variety of starting materialsincluding, but not limited to gases, minerals, and plastics.Nanocomposite technology provides the benefit of increased physicalproperties. Nanocomposites can provide higher heat distortiontemperatures, less shrinkage, less warping, electrical conductivity andbetter fire performance. The nanocomposites utilized in the flameretardant material can include an organic-inorganic complex of material.The flame retardant material can be composed of a nanocomposite materialcomprising a polymer material integrated with a clay between 0.1% and20% by weight of the nanocomposite. The weight of the clay used in thenanocomposite comprising the flame retardant material also can includeclay between 0.1% and 10% and clay between 10% and 20% by weight of thenanocomposite. The clay utilized can include a silicate or silicatederivative such as montmorillonite (alumino-silicate). Nanocompositetechnology has demonstrated a significant reduction in heat releaserates on the order of 50 to 75% while increasing stiffness, heatdistortion temperatures, cold temperature impact and other barrierproperties. Nanocomposites also can be utilized in conjunction withflame retardant resins. Flame retardant resins further enhance the fireresistance of pallets. Examples of fire performance enhancing resintechnologies used are zirconia, boron oxides, polybenzoxazine, polymersand carbonsilicone resin additives.

[0013] The flame retardant material can be adhered to the pallet memberutilizing a variety of processes well known within the industry. Forexample, in-mold processing, extrusion, co-extrusion, lamination, andautoclaving are available techniques that are suitable for adhering aflame retardant material to a pallet member. Application of flameretardant material to a pallet member is an effective mechanism forincreasing the fire resistance of the pallet assembly and reducingaccompanying safety hazards associated with low fire resistance, whilealso exceeding fire performance standards for pallets under UnderwritersLaboratory UL 2335 protocol for pallets.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The invention may be better understood by referring to thefollowing description taken in conjunction with the accompanyingdrawings, it being understood, however, that the invention is notlimited to the precise arrangements and instrumentalities shown.

[0015]FIG. 1 shoes a front view of a pallet member without a flameretardant material;

[0016]FIG. 2 shows a front view of a pallet member having a flameretardant material applied to pallet member; and

[0017]FIG. 3 shows a front view of a pallet member having a flameretardant material between surfaces of a pallet member.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0018] The present invention relates to an apparatus and method of fireblocking in a pallet assembly 10. The fire blocking of a pallet member12 enhances the physical attributes of the pallet assembly 10 whileproviding flame retardancy.

[0019] A pallet assembly 10, according to the invention comprises atleast one pallet member 12 having external surfaces 16 and a flameretardant material 14 affixed to at least one pallet member 12 so as tosubstantially cover all of the external surfaces 16 of the pallet member12. A pallet can include a container, tote bin, or any other suitabledevice used for the storage and transportation of items.

[0020] In accordance with the invention, a method of fire blocking apallet assembly 10 comprises the steps of providing a pallet assembly 10that can include at least one pallet member 12 having external surfaces16. The next step can include affixing a flame retardant material 14 toat least one pallet member 12 so as to substantially cover all of theexternal surfaces 16 of the pallet member 12.

[0021]FIG. 1 and FIG. 2 depict an embodiment of the present inventionhaving a flame retardant material 14 being utilized to cover a palletmember 12. As shown in FIG. 2, the flame retardant material 14 is usedto cover the surface of the pallet member 12. The type of flameretardant material 14 used in this embodiment is a flame retardantfabric 18. The flame retardant fabric 18 provides a protective coveringfor the underlying pallet member 12, as depicted in FIG. 2. Applicationof the flame retardant fabric 18 includes the preparation of a suitableflame retardant fabric 18 to meet the physical dimensions of the palletmember 12 or entire pallet to be covered. The individual components ofthe pallet member 12 can be fabricated individually or as an entireunit. For example, a pallet member 12 that has a lower surface and anupper surface can be entirely fabricated by covering both the lower andupper surface of the pallet member 12, as shown in FIG. 2.Alternatively, the lower surface can be fabricated while leaving theupper surface exposed, or the upper surface can be fabricated whileleaving the lower surface exposed. Dependent on the particular use ofthe pallet member 12, it can be more suitable and economical to coveronly one surface of a pallet member 12 with a flame retardant material14. For instance, in a warehouse facility where stacking of pallets canbe limited to single layer stacking, and the most likely fire hazard ispresented from the ground or other lower surface, one may elect only tocover the lower surface of the pallet member 12. Flame retardantmaterial used to cover a pallet member 12 can also include flameretardant resins within various components of the pallet member 12. Forexample, the upper surface of the pallet member 12 can include a flameretardant resin while the remaining portions, such as the lower surface,can comprise other materials. Other suitable flame retardant materialcan include flame retardant fabrics, films and gaskets. Flame retardantmaterial, such as intumescent films, coatings and foams can be placedbetween the upper surface and lower surface of a pallet member 12 toprovide additional flame resistance, as depicted in FIG. 3. Flameretardant material can also be placed to fill voids and spaces withinthe pallet member 12. Processes such as blow molding, welding, and twinsheet thermoforming can be utilized to incorporate the flame retardantmaterials into the pallet member 12.

[0022] Suitable types of flame retardant fabrics that can be utilized tocover a pallet member 12 can include fabrics comprising polymeric fibersand flame retardant polymers. A flame retardant polymer can includepolyetaraflouraethylene. An example of a flame retardant synthetic fiberutilized can include a polyolefin fiber. Synthetic fibers are engineeredto transport and manage moisture, thermoregulate, stretch for comfort,provide personal safety, inhibit the growth of bacteria, and more.Polyolefin fiber is extremely strong, abrasion resistant and offers thehighest insulating ability. Polyolefin fibers also possess a lightweight. The weight of the flame retardant material 14 used can be animportant factor to consider when designing a pallet assembly 10 toensure meeting weight specifications for the particular pallet. As shownin FIG. 3, a flame retardant liquid 20 also can comprise the flameretardant material 14 used to cover the pallet member 12. For instance,intumescent materials can be provided as the flame retardant material14. Covering a pallet member 12 utilizing the flame retardant liquid 20can be applied with a brush, roller or spray similar to application ofordinary paint. The required coating thickness may depend on thesubstrate, severity of the heat exposure, and level of protectiondesired. For example, coating visually exposed pallet members 12 byspraying flame retardant intumescent paint directly to a pallet member12 can be used where the pallet design calls for a thin, aesthetic,decorative look. The intumescent material 14 can be applied to a palletmember 12 and cause the surface to bubble to create a barrier betweenthe fire and the treated material, thereby providing significantprotection for the pallet member 12. In an embodiment of the presentinvention shown in FIG. 4, a metal 22 can be included as a suitableflame retardant material 14. Stainless steel, copper, and aluminum areexamples of metals that exhibit strong heat resistance while maintainingmalleability which allow these metals to be integrated into a palletassembly 10. In some pallet designs it may be advantageous to use metal22 as the covering material in the pallet assembly 10 because of theintended use of the particular pallet. For instance, many wooden palletsoften deteriorate and fall apart over time and require constantmaintenance. Consequently, wood might not be optimally suited totransport highly flammable cargo. However, given the choice, metal 22 asthe flame retardant material 14 in a pallet assembly 10 would likelyprovide the best protection under the given circumstances. The thicknessof metal layers applied to the pallet member 12 can be adjusted to suitthe specific needs of the pallet, along with consideration totransportation and storage concerns.

[0023] The present invention can include nanocomposite technology as acomponent of the flame retardant material 14 utilized in covering apallet member 12. Nanocomposites utilize many different materialsintermingled on a nanometer scale. Nanocomposites can be made from avariety of starting materials including, but not limited to gases,minerals, and plastics. Nanocomposite technology provides the benefit ofincreased physical properties. Nanocomposites can provide higher heatdistortion temperatures, less shrinkage, less warping, electricalconductivity and better fire performance. The nanocomposites utilized inthe flame retardant material 14 can be incorporated into a variety ofmaterials. Nanocomposites can comprise an organic-inorganic complex ofmaterial. The flame retardant material 14 can be composed of ananocomposite material comprising a polymer material integrated with aclay between 0.1% and 20% by weight of the nanocomposite. The weight ofthe clay used in the nanocomposite comprising the flame retardantmaterial 14 also can include clay between 0.1% and 10% and clay between10% and 20% by weight of the nanocomposite. The clay utilized caninclude a silicate or silicate derivative such as montmorillonite(alumino-silicate). Nanocomposite technology has demonstrated asignificant reduction in heat release rates on the order of 50 to 75%while increasing stiffness, heat distortion temperatures, coldtemperature impact and other barrier properties. Nanocomposites also canbe utilized in conjunction with flame retardant resins. Flame retardantresins further enhance the fire resistance of the pallets. Examples offire performance enhancing resin technologies used are zirconia, boronoxides, polybenzoxazine, polymers and carbon-silicone resin additives.

[0024] The present invention can be useful in a protect various forms ofthe pallet assembly 10 that can include, but are not limited towarehouse pallets, totes, bins, and intermediate bulk containers.Additionally, the invention can be used in conjunction with a multitudeof pallet designs of unlimited dimensions. The Grocery ManufacturingAssociation sets specific requirements for pallets that are used in thefood and beverage industry. The Grocery Manufacturing Association (GMA)is one of the largest association of food, beverage and consumer productcompanies. The GMA assists in establishing food and nutritional policythroughout the country, which includes establishing palletspecifications. Pallet specifications as established by the GroceryManufacturing Association require that a pallet be exactly 48″×40″; havetrue 4-way entry; accommodate pallet racks; have a smooth, non-skid, topload bearing surface having at least 85% coverage and should be flat; abottom loading surface and have cuts for pallet jack wheels from foursides; rackable from 48″ and 40″ dimension; must be recyclable; desiredweight under 50 pounds; have a load capacity of 2,800 pounds; capable ofbearing 2,800 pound loads safely in stacks of five loads high racking;and weather and moisture resistant. In an embodiment of the presentinvention featuring certain pallet designs, the pallets meet the GroceryManufacturing Association requirements.

[0025] The flame retardant material 14 can be adhered to the palletmember 12 utilizing a variety of processes suitable in the industry. Forexample, in-mold processing, extrusion, co-extrusion, lamination, andautoclaving are available techniques that are suitable for adhering aflame retardant material 14 to a pallet member 12. Application of flameretardant material 14 to a pallet member 12 is an effective mechanism inincreasing the fire resistance of pallets and reducing accompanyingsafety hazards associated with low fire resistance, while also exceedingfire performance standards for pallets under Underwriters Laboratory UL2335 protocol for pallets.

What is claimed is:
 1. A method of fire blocking a pallet assembly, saidmethod comprising the steps of: providing a pallet assembly comprisingat least one pallet member having external surfaces; and affixing aflame retardant material to said at least one pallet member so as tosubstantially cover all of said external surfaces of said pallet member.2. The method according to claim 1, wherein said affixing step providingsaid flame retardant material includes a flame retardant fabric.
 3. Themethod according to claim 2, wherein said affixing step providing saidflame retardant fabric further comprises a blend of polymeric fibers. 4.The method according to claim 2, wherein said affixing step furtherprovides preparing said flame retardant fabric adapted to dimensions ofsaid pallet member.
 5. The method according to claim 2, furthercomprising the step of fabricating the individual components of saidpallet member with said flame retardant fabric.
 6. The method accordingto claim 1, wherein said affixing step providing said flame retardantmaterial includes a flame retardant liquid.
 7. The method of claim 4,wherein said affixing step providing said flame retardant liquid furthercomprises an intumescent material.
 8. The method according to claim 1,wherein said affixing step providing said flame retardant material isselected from the group including a flame retardant solid and a flameretardant foam.
 9. The method according to claim 1, wherein saidaffixing step providing said flame retardant material includes a flameretardant polymer.
 10. The method according to claim 9, wherein saidaffixing step providing said flame retardant polymer further comprisespolyetaraflouraethylene.
 12. The method according to claim 1, whereinsaid affixing step providing said flame retardant material includes aflame retardant synthetic fiber.
 13. The method according to claim 12,wherein said affixing step providing said flame retardant syntheticfiber further comprises a polyolefin fiber.
 14. The method according toclaim 12, wherein said affixing step providing said flame retardantsynthetic fiber further comprises a polyester fiber.
 15. The methodaccording to claim 12, wherein said affixing step providing said flameretardant synthetic fiber further comprises a melamine fiber.
 16. Themethod according to claim 1, wherein said affixing step providing saidflame retardant material includes a flame retardant metal.
 17. Themethod according to claim 16, wherein said affixing step providing saidflame retardant metal is selected from the group consisting of stainlesssteel, copper and aluminum.
 18. The method according to claim 1, whereinsaid affixing step providing said flame retardant material is composedof a nanocomposite comprised of a clay that includes a silicatederivative.
 19. The method according to claim 1, wherein said affixingstep providing said flame retardant material is composed of ananocomposite material comprising a polymer material integrated with aclay, said clay between 0.1% and 20% weight of said nanocomposite. 20.The method according to claim 1, wherein said affixing step providingsaid flame retardant material is composed of a nanocomposite materialcomprising a polymer material integrated with a clay, said clay between0.1% and 10% weight of said nanocomposite.
 21. The method according toclaim 1, wherein said affixing step providing said flame retardantmaterial is composed of a nanocomposite material comprising a polymermaterial integrated with a clay, said clay between 10% and 20% weight ofsaid nanocomposite.
 22. The method according to claim 1, furthercomprising the step of in-mold processing to adhere flame retardantmaterial to said surface of said pallet member.
 23. The method accordingto claim 1, further comprising the step of extrusion to adhere flameretardant material to said surface of said pallet member.
 24. The methodaccording to claim 1, further comprising the step of co-extrusion toadhere flame retardant material to said surface of said pallet member.25. The method according to claim 1, further comprising the step oflaminating to adhere flame retardant material to said surface of saidpallet member.
 26. The method according to claim 1, further comprisingthe step of autoclaving to adhere flame retardant material to saidsurface of said pallet member.
 27. A pallet assembly comprising: atleast one pallet member having external surfaces; and a flame retardantmaterial affixed to said at least one pallet member so as tosubstantially cover all of said external surfaces of said pallet member.28. The pallet assembly of claim 27, wherein said flame retardantmaterial includes a flame retardant fabric.
 29. The pallet assembly ofclaim 27, wherein said flame retardant fabric comprises a blend ofpolymeric fibers.
 30. The pallet assembly of claim 27, wherein saidflame retardant material includes a flame retardant liquid.
 31. Thepallet assembly of claim 30, wherein said flame retardant liquidcomprises an intumescent material.
 32. The pallet assembly of claim 27,wherein said flame retardant material includes a flame retardantpolymer.
 33. The pallet assembly of claim 32, wherein said flameretardant polymer comprises polyetaraflouraethylene.
 34. The palletassembly of claim 27, wherein said flame retardant material includes aflame retardant synthetic fiber.
 35. The pallet assembly of claim 34,wherein said flame retardant synthetic fiber is selected from the groupincluding polyolefin fiber, melamine fiber and polyester fiber.
 36. Thepallet assembly of claim 27, wherein said flame retardant materialincludes a flame retardant metal.
 37. The pallet assembly of claim 36,wherein said flame retardant metal is selected from the group consistingof stainless steel, copper and aluminum.
 38. The pallet assembly ofclaim 27, wherein said flame retardant material is composed of ananocomposite comprised of a clay that includes a silicate derivative.39. The pallet assembly of claim 27, wherein said flame retardantmaterial is composed of a nanocomposite material comprising a polymermaterial integrated with a clay, said clay between 0.1% and 20% weightof said nanocomposite.
 40. The pallet assembly of claim 27, wherein saidflame retardant material is composed of a nanocomposite materialcomprising a polymer material integrated with a clay, said clay between0.1% and 10% weight of said nanocomposite.
 41. The pallet assembly ofclaim 27, wherein said flame retardant material is composed of ananocomposite material comprising a polymer material integrated with aclay, said clay between 10% and 20% weight of said nanocomposite. 42.The pallet assembly of claim 27, wherein said flame retardant materialis in-molded to adhere said flame retardant material to said surface ofsaid pallet member.
 43. The pallet assembly of claim 27, wherein saidflame retardant material is extruded to adhere said flame retardantmaterial to said surface of said pallet member.
 44. The pallet assemblyof claim 27, wherein said flame retardant material is co-extruded toadhere said flame retardant material to said surface of said palletmember.
 45. The pallet assembly of claim 27, wherein said flameretardant material is laminated to adhere said flame retardant materialto said surface of said pallet member.